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KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05622-11 – PDF DOWNLOAD
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KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05622-11 – PDF DOWNLOAD
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KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05622-11 – PDF DOWNLOAD
Language : English
Pages : 1748
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05622-11 – PDF DOWNLOAD
Cover........................................................................................................................................ 1 00 Index and foreword ................................................................................................................... 3 Index ............................................................................................................................... 4 Foreword, safety and general information ............................................................................................ 16 Important safety notice ......................................................................................................... 16 How to read the shop manual ..................................................................................................... 23 Explanation of terms for maintenance standard ................................................................................... 25 Handling equipment of fuel system devices ....................................................................................... 27 Handling of intake system parts ................................................................................................. 28 Handling of hydraulic equipment ................................................................................................. 29 Method of disconnecting and connecting of push-pull type coupler ................................................................ 31 Handling of electrical equipment ................................................................................................ 34 How to read electric wire code .................................................................................................. 42 Precautions when performing operation ........................................................................................... 45 Practical use of KOMTRAX ........................................................................................................ 50 Standard tightening torque table ................................................................................................ 51 List of abbreviation ............................................................................................................ 57 Conversion table ................................................................................................................ 62 01 Specification ........................................................................................................................ 67 Table of contents ................................................................................................................... 68 Specifications ...................................................................................................................... 69 Specification drawing ........................................................................................................... 69 Working range drawing ........................................................................................................... 70 Specification ................................................................................................................... 71 Table of weight ................................................................................................................. 74 Table of fuel, coolant and lubricants ........................................................................................... 75 10 Structure and function ............................................................................................................... 77 Table of contents ................................................................................................................... 78 Engine and cooling system ........................................................................................................... 79 Engine-related parts ............................................................................................................ 79 KVGT ............................................................................................................................ 81 EGR system piping drawing ....................................................................................................... 87 EGR system circuit diagram ...................................................................................................... 89 EGR valve ....................................................................................................................... 90 EGR cooler ...................................................................................................................... 92 KCCV layout drawing ............................................................................................................. 94 KCCV ventilator ................................................................................................................. 96 KDPF ............................................................................................................................ 98 Cooling system .................................................................................................................. 102 Cooling fan pump ................................................................................................................ 105 Cooling fan motor ............................................................................................................... 115 Power train ......................................................................................................................... 123 Power train ..................................................................................................................... 123 Swing circle .................................................................................................................... 125 Swing machinery ................................................................................................................. 126 Final drive ..................................................................................................................... 128 Undercarriage and frame ............................................................................................................. 130 Track frame and idler cushion ................................................................................................... 130 Hydraulic system .................................................................................................................... 132 Hydraulic component layout ...................................................................................................... 132 Valve control ................................................................................................................... 134 Hydraulic tank .................................................................................................................. 136 CLSS ............................................................................................................................ 139 Main pump ....................................................................................................................... 144 Control valve ................................................................................................................... 167 Swing motor ..................................................................................................................... 222 Travel motor .................................................................................................................... 233 PPC valve ....................................................................................................................... 248 Solenoid valve .................................................................................................................. 267 Attachment circuit selector valve ............................................................................................... 270 Center swivel joint ............................................................................................................. 281 Accumulator ..................................................................................................................... 283 Work equipment ...................................................................................................................... 284 Work equipment .................................................................................................................. 284 Work equipment shims ............................................................................................................ 285 Bucket play adjustment shim ..................................................................................................... 286 Anti-drop valve...................................................................................................................... 273 Cab and its attachments ............................................................................................................. 287 Cab mount and cab tipping stopper ............................................................................................... 287 ROPS cab ........................................................................................................................ 288 Electrical system ................................................................................................................... 289 Electrical control system ....................................................................................................... 289 Machine monitor system .......................................................................................................... 338 KOMTRAX system .................................................................................................................. 356 Sensor .......................................................................................................................... 358 20 Standard value tables ................................................................................................................ 377 Table of contents ................................................................................................................... 378 Standard service value table ........................................................................................................ 379 Standard value table for engine ................................................................................................. 379 Standard value table for machine ................................................................................................ 381 30 Testing and adjusting ................................................................................................................ 395 Table of contents ................................................................................................................... 396 Related information on testing and adjusting ........................................................................................ 399 Tools for testing and adjusting ................................................................................................. 399 Sketch of tools for testing and adjusting ....................................................................................... 404 Engine and cooling system ........................................................................................................... 406 Testing engine speed ............................................................................................................ 406 Testing boost pressure .......................................................................................................... 407 Testing exhaust gas color ....................................................................................................... 409 Testing mass air flow and temperature sensor..................................................................................... 411 Testing and adjusting valve clearance ........................................................................................... 413 Testing compression pressure .................................................................................................... 416 Testing blowby pressure ......................................................................................................... 418 Testing engine oil pressure ..................................................................................................... 419 Testing EGR valve and KVGT oil pressure ......................................................................................... 420 Testing fuel pressure ........................................................................................................... 421 Testing fuel leakage and return ................................................................................................. 423 Bleeding air from fuel system ................................................................................................... 426 Testing fuel circuit for leakage ................................................................................................ 428 Handling cylinder cutout mode operation ......................................................................................... 429 Handling no-injection cranking operation ........................................................................................ 430 Testing and adjusting air conditioner compressor belt tension ................................................................... 431 Replacing alternator belt ....................................................................................................... 432 Fuel doser cleaning procedure ................................................................................................... 433 Writing compensation values at replacement of injector and engine controller .................................................... 436 Power train ......................................................................................................................... 440 Testing swing circle bearing clearance .......................................................................................... 440 Undercarriage and frame ............................................................................................................. 441 Testing and adjusting track tension ............................................................................................. 441 Hydraulic system .................................................................................................................... 442 Releasing remaining pressure from hydraulic circuit.............................................................................. 442 Releasing remaining pressure onmachines equipped with anti-dropvalve for arm with maximum arm INposture.......................... 444 Releasing remaining pressure onmachines equipped with anti-dropvalve for arm with maximum armOUT posture......................... 445 Testing and adjusting oil pressure in work equipment, swing and travel circuits ................................................. 447 Testing oil pressure in control circuit ......................................................................................... 452 Testing and adjusting oil pressure in pump PC control circuit ................................................................... 453 Testing and adjusting oil pressure in pump LS control circuit ................................................................... 456 Testing output pressure of solenoid valve ....................................................................................... 461 Testing PPC valve output pressure ............................................................................................... 465 Adjusting play of work equipment and swing PPC valves ........................................................................... 467 Testing pump swash plate sensor ................................................................................................. 468 Testing fan speed ............................................................................................................... 469 Testing fan pump circuit oil pressure ........................................................................................... 470 Checking fan pump EPC current ................................................................................................... 471 Testing fan pump EPC solenoid valve output pressure ............................................................................. 472 Isolating the parts causing hydraulic drift in work equipment ................................................................... 473 Testing oil leakage ............................................................................................................. 475 Bleeding air from hydraulic circuit ............................................................................................. 478 Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side).................. 481 Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side)....................................... 483 Replacing accumulator bladder on high pressure side for accumulator piping....................................................... 485 Cab and its attachments ............................................................................................................. 491 Testing cab tipping stopper ..................................................................................................... 491 Adjusting mirrors ............................................................................................................... 492 Electrical system ................................................................................................................... 495 Special functions of machine monitor ............................................................................................ 495 Adjusting rearview camera angle ................................................................................................. 564 Handling voltage circuit of engine controller ................................................................................... 566 Handling battery disconnect switch .............................................................................................. 567 Testing diodes .................................................................................................................. 568 Pm clinic ........................................................................................................................... 569 Check sheet ..................................................................................................................... 573 40 Troubleshooting ...................................................................................................................... 579 Table of contents ................................................................................................................... 580 Related information on troubleshooting .............................................................................................. 587 Troubleshooting points .......................................................................................................... 587 Sequence of events in troubleshooting ........................................................................................... 589 Checks before troubleshooting ................................................................................................... 591 Inspection procedure before troubleshooting ..................................................................................... 593 Preparation for troubleshooting of electrical system ............................................................................ 610 Classification and procedure for troubleshooting ................................................................................ 616 Symptom and troubleshooting numbers ............................................................................................. 619 Information in troubleshooting table ............................................................................................ 622 Connector list and layout ....................................................................................................... 624 Connector contact identification ................................................................................................ 635 T-branch box and T-branch adapter table ......................................................................................... 674 Connection table of fuse box .................................................................................................... 679 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................................................... 681 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................. 684 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ..................................... 685 Failure codes table ............................................................................................................. 686 Troubleshooting by failure code (Display of code) ................................................................................... 695 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................. 695 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................ 696 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................. 697 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................ 698 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................... 699 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................... 700 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ..................................................................... 701 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................ 702 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................ 703 Failure code [879GKX] Refrigerant Abnormality ................................................................................... 704 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................... 705 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................... 706 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................... 707 Failure code [A1U0N3] HC Desorb Request 1 ....................................................................................... 708 Failure code [A1U0N4] HC Desorb Request 2 ....................................................................................... 710 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................... 712 Failure code [AB00KE] Charge Voltage Low ........................................................................................ 714 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................... 716 Failure code [B@BAZK] Eng Oil Level Low ......................................................................................... 717 Failure code [B@BCNS] Eng Water Overheat ........................................................................................ 718 Failure code [B@BCZK] Eng Water Level Low ....................................................................................... 719 Failure code [B@HANS] Hyd Oil Overheat .......................................................................................... 721 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................... 722 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................ 723 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................. 725 Failure code [CA131] Throttle Sensor High Error ................................................................................. 727 Failure code [CA132] Throttle Sensor Low Error .................................................................................. 729 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................ 731 Failure code [CA141] Eng Oil Press Sensor Low Error ............................................................................. 733 Failure code [CA144] Coolant Temp Sens High Error ............................................................................... 735 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................ 737 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................. 739 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................. 741 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................. 743 Failure code [CA221] Ambient Press Sensor High Error ............................................................................ 745 Failure code [CA222] Ambient Press Sensor Low Error ............................................................................. 747 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................ 749 Failure code [CA234] Eng Overspeed .............................................................................................. 750 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................... 751 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................... 752 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................... 753 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................ 754 Failure code [CA273] PCV2 Short Error ........................................................................................... 755 Failure code [CA274] PCV2 Open Error ............................................................................................ 756 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................... 757 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................... 759 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................... 761 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................... 763 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................................... 765 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................................... 767 Failure code [CA343] ECM Critical Internal Failure .............................................................................. 769 Failure code [CA351] Injectors Drive Circuit Error .............................................................................. 770 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................. 771 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................ 773 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................. 775 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................ 777 Failure code [CA441] Battery Voltage Low Error .................................................................................. 778 Failure code [CA442] Battery Voltage High Error ................................................................................. 780 Failure code [CA449] Rail Press Very High Error ................................................................................. 781 Failure code [CA451] Rail Press Sensor High Error ............................................................................... 782 Failure code [CA452] Rail Press Sensor Low Error ................................................................................ 784 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................ 786 Failure code [CA516] Rail Press Sens Sup Volt Low Error ......................................................................... 788 Failure code [CA553] Rail Press High Error ...................................................................................... 790 Failure code [CA555] Crankcase Press High Error 1 ............................................................................... 791 Failure code [CA556] Crankcase Press High Error 2 ............................................................................... 792 Failure code [CA559] Rail Press Low Error ....................................................................................... 793 Failure code [CA595] Turbo Speed High Error 2 ................................................................................... 797 Failure code [CA687] Turbo Speed Low Error ...................................................................................... 798 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................. 800 Failure code [CA691] Intake Temperature Sensor High Error ....................................................................... 802 Failure code [CA692] Intake Temperature Sensor Low Error ........................................................................ 804 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................ 806 Failure code [CA698] ECM Int Temp Sensor Low Error .............................................................................. 807 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................ 808 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................ 809 Failure code [CA1117] Persistent Data Lost Error ................................................................................ 811 Failure code [CA1664] KDOC Malfunction .......................................................................................... 812 Failure code [CA1691] Regeneration Ineffective .................................................................................. 815 Failure code [CA1695] Sens supply 5 volt high error ............................................................................. 818 Failure code [CA1696] Sens supply 5 volt low error .............................................................................. 819 Failure code [CA1843] Crankcase Pressure Sensor High Error ...................................................................... 821 Failure code [CA1844] Crankcase Press Sensor Low Error .......................................................................... 823 Failure code [CA1879] KDPF Delta Pressure Sensor High Error ..................................................................... 825 Failure code [CA1881] KDPF Delta Pressure Sensor Low Error ...................................................................... 827 Failure code [CA1883] KDPF Delta Pressure Sensor In Range Error ................................................................. 829 Failure code [CA1921] KDPF Soot Load High Error 1 ............................................................................... 832 Failure code [CA1922] KDPF Soot Load High Error 2 ............................................................................... 835 Failure code [CA1923] Dosing Fuel Valve 1 High Error ............................................................................ 840 Failure code [CA1924] Dosing Fuel Valve 1 Low Error ............................................................................. 842 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ........................................................................ 844 Failure code [CA1927] Dosing Fuel Press Sens High Error ......................................................................... 846 Failure code [CA1928] Dosing Fuel Press Sens Low Error .......................................................................... 848 Failure code [CA1942] Crankcase Press Sens In Range Error ....................................................................... 850 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ........................................................................... 851 Failure code [CA1977] Fuel Doser Open/Short Error ............................................................................... 854 Failure code [CA1993] KDPF Delta Pressure Low Error ............................................................................. 856 Failure code [CA2185] Throt Sensor Sup Volt High Error .......................................................................... 858 Failure code [CA2186] Throt Sensor Sup Volt Low Error ........................................................................... 860 Failure code [CA2249] Rail Press Very Low Error ................................................................................. 862 Failure code [CA2265] Fuel feed pump open circuit error ......................................................................... 863 Failure code [CA2266] Fuel feed pump short circuit error ........................................................................ 865 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................. 867 Failure code [CA2272] EGR Valve Pos Sens Low Error .............................................................................. 869 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................. 871 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................ 873 Failure code [CA2357] EGR Valve Servo Error ..................................................................................... 875 Failure code [CA2381] KVGT Pos Sens High Error .................................................................................. 876 Failure code [CA2382] KVGT Pos Sens Low Error ................................................................................... 878 Failure code [CA2383] KVGT Solenoid Open Error .................................................................................. 880 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................. 882 Failure code [CA2387] VGT Servo Error ........................................................................................... 884 Failure code [CA2555] Grid Htr Relay Open Circuit Error ......................................................................... 887 Failure code [CA2556] Grid Htr Relay Short Circuit Error ........................................................................ 889 Failure code [CA2637] KDOC Face Plugging ........................................................................................ 891 Failure code [CA2639] Manual Stationary Regeneration Request .................................................................... 893 Failure code [CA2732] Dosing Fuel Valve 2 High Error ............................................................................ 896 Failure code [CA2733] Dosing Fuel Valve 2 Low Error ............................................................................. 898 Failure code [CA2741] Dosing Fuel Valve Swap Error .............................................................................. 900 Failure code [CA2765] Inj Trim Data Error ....................................................................................... 901 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ........................................................................... 902 Failure code [CA2881] Dosing Fuel Pressure Low Error 1 .......................................................................... 905 Failure code [CA3133] KDPF Outlet Pressure Sensor High Error .................................................................... 910 Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error ..................................................................... 912 Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error ................................................................ 914 Failure code [CA3167] Fuel Doser Degradation .................................................................................... 918 Failure code [CA3251] KDOC Inlet Temperature High Error ......................................................................... 921 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................ 924 Failure code [CA3254] KDOC Outlet Temp High Error 1 ............................................................................. 927 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................ 930 Failure code [CA3256] KDPF Outlet Temp High Error 1 ............................................................................. 934 Failure code [CA3311] KDOC Outlet Temp High Error 2 ............................................................................. 937 Failure code [CA3312] KDPF Outlet Temp High Error 2 ............................................................................. 940 Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error ................................................................... 943 Failure code [CA3314] KDOC Inlet Temperature Sensor High Error .................................................................. 946 Failure code [CA3315] KDOC Intlet Temperature Sensor In Range Error ............................................................. 950 Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error .................................................................. 955 Failure code [CA3317] KDOC Outlet Temperature Sensor High Error ................................................................. 958 Failure code [CA3318] KDOC Outlet Temp Sensor In Range Error .................................................................... 962 Failure code [CA3319] KDPF Outlet Temperature Sensor High Error ................................................................. 967 Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error .................................................................. 971 Failure code [CA3322] KDPF Outlet Temp Sensor In Range Error .................................................................... 974 Failure code [CA3419] Mass Air Flow Sensor Power Supply High Error .............................................................. 979 Failure code [CA3421] Mass Air Flow Sensor Power Supply Low Error ............................................................... 981 Failure code [D110KB] Battery Relay Drive S/C ................................................................................... 983 Failure code [D19JKZ] Personal Code Relay Abnormality ........................................................................... 985 Failure code [D811MC] KOMTRAX Error ............................................................................................. 988 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................. 989 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ..................................................................... 990 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .................................................................... 992 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..................................................................................... 993 Failure code [DA20MC] Pump Controller Malfunction ............................................................................... 994 Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................................. 995 Failure code [DA25KP] 5V Sensor1 Power Abnormality .............................................................................. 997 Failure code [DA29KQ] Model Selection Abnormality ............................................................................... 999 Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................................................1002 Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ...................................................................1004 Failure code [DA2QKR] CAN2 Discon (Pump Con) ....................................................................................1005 Failure code [DA2RKR] CAN1 Discon ( Pump Con) ...................................................................................1008 Failure code [DAF0MB] Monitor ROM Abnormality ...................................................................................1009 Failure code [DAF0MC] Monitor Error .............................................................................................1010 Failure code [DAF8KB] Camera Power Supply Short Circuit .........................................................................1011 Failure code [DAF9KQ] Model Selection Abnormality ...............................................................................1013 Failure code [DAFGMC] GPS Module Error ..........................................................................................1014 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) .....................................................................1015 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ....................................................................1017 Failure code [DAFQKR] CAN2 Discon (Monitor) .....................................................................................1018 Failure code [DAZ9KQ] AC Model Selection Abnormality ............................................................................1019 Failure code [DAZQKR] CAN2 Discon (AC) ..........................................................................................1020 Failure code [DB2QKR] CAN2 Discon (Engine Con) ..................................................................................1025 Failure code [DB2RKR] CAN1 Discon (Engine Con) ..................................................................................1030 Failure code [DGH2KA] Hyd Oil Temp Sensor Open ..................................................................................1035 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ..............................................................................1037 Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ..................................................................1039 Failure code [DHPAMA] Pump Press Sensor Abnormality .............................................................................1041 Failure code [DHPBMA] R Pump Press Sensor Abnormality ...........................................................................1044 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ...............................................................................1047 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ..................................................................1049 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality ...................................................................1052 Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality .......................................................................1055 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality ......................................................................1058 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality ......................................................................1061 Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality ......................................................................1064 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ..................................................................1067 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ..................................................................1070 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ..................................................................1073 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality ..................................................................1076 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ..................................................................1079 Failure code [DKR0MA] F pump S/P sensor Abnormality .............................................................................1082 Failure code [DKR1MA] R pump S/P sensor Abnormality .............................................................................1084 Failure code [DLM3KA] Fan speed sensor: Open circuit ............................................................................1086 Failure code [DLM3KB] Fan Speed Sensor Short Circuit ............................................................................1087 Failure code [DLM3MB] Fan Control Mismatch ......................................................................................1088 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ...................................................................1089 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ...................................................................1091 Failure code [DV20KB] Travel Alarm Short Circuit ................................................................................1093 Failure code [DW43KA] Travel Speed Sol Open Circuit .............................................................................1095 Failure code [DW43KB] Travel Speed Sol Short Circuit ............................................................................1097 Failure code [DW45KA] Swing Brake Sol Open Circuit ..............................................................................1099 Failure code [DW45KB] Swing Brake Sol Short Circuit .............................................................................1102 Failure code [DW7BKA] Fan Reverse Sol Open Circuit ..............................................................................1104 Failure code [DW7BKB] Fan Reverse Sol Short Circuit .............................................................................1106 Failure code [DW91KA] Travel Junction Sol Open Circuit ..........................................................................1108 Failure code [DW91KB] Travel Junction Sol Short Circuit .........................................................................1110 Failure code [DWA2KA] Attachment Sol Open Circuit ...............................................................................1112 Failure code [DWA2KB] Attachment Sol Short Circuit ..............................................................................1114 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ...........................................................................1116 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ..........................................................................1118 Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit ...................................................................1120 Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit ..................................................................1122 Failure code [DWK8KA] Swing C/O Solenoid Open Circuit ...........................................................................1124 Failure code [DWK8KB] Swing C/O Solenoid Short Circuit ..........................................................................1126 Failure code [DX16KA] Fan Pump EPC Sol Open Circuit .............................................................................1128 Failure code [DX16KB] Fan Pump EPC Sol Short Circuit ............................................................................1130 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ...............................................................................1132 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ..............................................................................1134 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ...............................................................................1136 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ..............................................................................1138 Failure code [DXE0KA] LS-EPC Sol Open Circuit ...................................................................................1140 Failure code [DXE0KB] LS-EPC Sol Short Circuit ..................................................................................1142 Failure code [DXE4KA] Service Current EPC Disc. .................................................................................1144 Failure code [DXE4KB] Service Current EPC S/C ...................................................................................1145 Failure code [DXE5KA] Merge-divider Main Sol Open Circuit .......................................................................1146 Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ......................................................................1148 Failure code [DXE6KA] Merge-divider LS Sol Open Circuit .........................................................................1150 Failure code [DXE6KB] Merge-divider LS Sol Short Circuit ........................................................................1152 Failure code [DY20KA] Wiper Working Abnormality .................................................................................1154 Failure code [DY20MA] Wiper Parking Abnormality .................................................................................1156 Failure code [DY2CKB] Washer Drive Short Circuit ................................................................................1158 Failure code [DY2DKB] Wiper Drive (For) Short ...................................................................................1160 Failure code [DY2EKB] Wiper Drive (Rev) Short ...................................................................................1162 Troubleshooting of electrical system (E-mode) .......................................................................................1164 E-1 Engine does not start (Engine does not crank) ...............................................................................1164 E-2 Manual preheater does not operate ...........................................................................................1170 E-3 Automatic preheater does not operate ........................................................................................1173 E-4 While preheater is operating, engine preheating monitor does not light up ...................................................1175 E-5 While starting switch is turned ON, machine monitor displays nothing ........................................................1177 E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow ..........1180 E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow ....1181 E-8 Engine coolant temperature monitor lights up in white while engine is running ...............................................1182 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ................................................1183 E-10 Charge level monitor lights up in red while engine is running ..............................................................1184 E-11 Fuel level monitor lights up in red while engine is running ................................................................1185 E-12 Air cleaner clogging monitor lights up in yellow while engine is running ...................................................1186 E-13 Engine coolant temperature monitor lights up in red while engine is running ................................................1187 E-14 Hydraulic oil temperature monitor lights up in red while engine is running .................................................1188 E-15 Engine oil pressure monitor lights up in red while engine is running .......................................................1189 E-16 Fuel gauge display does not move from minimum or maximum ...................................................................1190 E-17 Display of fuel gauge differs from actual fuel level .......................................................................1191 E-18 Engine coolant temperature gauge display does not move from minimum or maximum .............................................1192 E-19 Display of engine coolant temperature gauge differs from actual coolant temperature ........................................1193 E-20 Hydraulic oil temperature gauge display does not move from minimum or maximum ..............................................1194 E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature .............................................1196 E-22 Machine monitor does not display partially .................................................................................1197 E-23 Function switch does not operate ...........................................................................................1198 E-24 Automatic warm-up system does not work (in cold weather) ...................................................................1199 E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off ....................1200 E-26 Auto-decelerator is not operated or canceled with lever ....................................................................1201 E-27 When working mode switch is operated, working mode selection screen is not displayed .......................................1202 E-28 When working mode is changed, setting of engine and hydraulic pump is not changed ..........................................1203 E-29 When travel speed switch is operated, travel speed monitor does not change .................................................1204 E-30 When travel speed selection is changed, actual travel speed does not change ................................................1205 E-31 Alarm buzzer cannot be canceled ............................................................................................1206 E-32 When starting switch is turned OFF, service meter is not displayed .........................................................1207 E-33 Machine monitor cannot be set in service mode ..............................................................................1208 E-34 All of work equipments, swing, and travel mechanism do not move ............................................................1209 E-35 All of work equipment, swing, and travel mechanism do not lock .............................................................1211 E-36 When swing brake cancel switch is set to CANCEL position, machine cannot swing .............................................1212 E-37 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position .............................1214 E-38 One-touch power maximizing function does not operate properly, or indicator not displayed on monitor .......................1216 E-39 One-touch power maximizing function is not cancelled .......................................................................1218 E-40 Alarm does not sound during travel .........................................................................................1219 E-41 Alarm does not stop sounding while machine is stopped ......................................................................1221 E-42 Horn does not sound ........................................................................................................1222 E-43 Horn does not stop sounding ................................................................................................1224 E-44 When wiper switch is operated, wiper monitor does not light up or go off ...................................................1225 E-45 When wiper switch is operated, windshield wiper does not operate ...........................................................1226 E-46 When window washer switch is operated, window washer does not operate ......................................................1228 E-47 Boom LOWER indicator is not displayed properly with monitoring function ....................................................1229 E-48 Arm OUT indicator is not displayed properly with monitoring function .......................................................1230 E-49 Arm IN indicator is not displayed properly with monitoring function ........................................................1231 E-50 Boom RAISE indicator is not displayed properly with monitoring function ....................................................1232 E-51 Bucket CURL indicator is not displayed properly with monitoring function ...................................................1233 E-52 Bucket DUMP indicator is not displayed properly with monitoring function ...................................................1234 E-53 Swing indicator is not displayed properly with monitoring function .........................................................1235 E-54 Travel indicator is not displayed properly with monitoring function ........................................................1236 E-55 Service indicator is not displayed properly with monitoring function .......................................................1237 E-56 Attachment hydraulic circuit cannot be changed .............................................................................1239 E-57 KOMTRAX system does not operate properly ...................................................................................1240 E-58 Machine push-up function cannot be canceled ................................................................................1242 E-59 Machine push-up function does not operate ..................................................................................1244 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................1245 Information described in troubleshooting table (H-mode) .........................................................................1245 System diagram of hydraulic equipment system ....................................................................................1246 Failure mode and cause table ....................................................................................................1248 H-1 Speed or power of all work equipment, swing, and travel is low. .............................................................1254 H-2 Engine speed lowers significantly or engine stalls ..........................................................................1256 H-3 Any of work equipment, swing and travel does not work .......................................................................1258 H-4 Unusual sound is heard from around hydraulic pump ...........................................................................1259 H-5 Fine control performance or response is poor ................................................................................1260 H-6 Speed or power of boom is low ...............................................................................................1261 H-7 Speed or power of arm is low ................................................................................................1265 H-8 Speed or power of bucket is low .............................................................................................1269 H-9 Work equipment does not move in single operation ............................................................................1272 H-10 Hydraulic drift of work equipment is large .................................................................................1273 H-11 Time lag of work equipment is large ........................................................................................1277 H-12 Other work equipment moves when one of work equipment is relieved ..........................................................1278 H-13 One-touch power maximizing function does not work ..........................................................................1279 H-14 Machine push-up function does not work .....................................................................................1280 H-15 In combined operation of work equipment , equipment having heavier load moves slower. ......................................1281 H-16 In combined operation of swing and boom RAISE, boom rising speed is low ....................................................1282 H-17 Travel speed drops largely in combined operation of swing and trave ........................................................1283 H-18 Machine does not travel straight ...........................................................................................1284 H-19 Travel speed is low ........................................................................................................1286 H-20 Machine is hard to steer or travel power is low ............................................................................1288 H-21 Travel speed does not change, or travel speed is too low or high ...........................................................1290 H-22 One of tracks does not run .................................................................................................1291 H-23 Upper structure does not swing .............................................................................................1292 H-24 Swing acceleration is poor or swing speed is low ...........................................................................1294 H-25 Upper structure overruns excessively when it stops swinging ................................................................1296 H-26 Shock is large when upper structure stops swinging .........................................................................1298 H-27 Large unusual noise is heard when upper structure stops swinging ...........................................................1299 H-28 Swing drift on a slope is large ............................................................................................1300 H-29 Attachment circuit cannot be changed .......................................................................................1302 H-30 Oil flow in attachment circuit cannot be controlled ........................................................................1303 H-31 Fan speed is abnormal (high, low, or 0 rpm) ................................................................................1304 H-32 Unusual noise is heard from around fan .....................................................................................1305 Troubleshooting of engine (S-mode) ..................................................................................................1306 Information mentioned in troubleshooting table (S mode) .........................................................................1306 S-1 When starting switch is turned to START position, engine is not cranked .....................................................1307 S-2 The engine cranks but exhaust smoke does not come out .......................................................................1308 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ......................1309 S-4 Engine startability is poor .................................................................................................1310 S-5 Engine does not pick-up smoothly ............................................................................................1312 S-6 Engine stops during operation ...............................................................................................1314 S-7 Engine runs rough or is unstable ............................................................................................1316 S-8 Engine lacks power ..........................................................................................................1317 S-9 KDPF gets clogged in a short time ...........................................................................................1319 S-10 Engine oil consumption is excessive ........................................................................................1321 S-11 Engine oil becomes contaminated early ......................................................................................1322 S-12 Fuel consumption is excessive ..............................................................................................1323 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................1324 S-14 Oil pressure drops .........................................................................................................1325 S-15 Fuel mixes into engine oil .................................................................................................1326 S-16 Water mixes into engine oil (milky) ........................................................................................1327 S-17 Coolant temperature rises too high (overheating) ...........................................................................1328 S-18 Unusual noise is heard .....................................................................................................1329 S-19 Vibration is excessive .....................................................................................................1330 S-20 Air cannot be bled from fuel circuit .......................................................................................1331 S-21 Active regeneration is executed frequently .................................................................................1332 S-22 Active regeneration takes a long time ......................................................................................1333 S-23 White smoke is exhausted during active regeneration ........................................................................1334 50 Disassembly and assembly .............................................................................................................1335 Table of contents ...................................................................................................................1336 Related information on disassembly and assembly .....................................................................................1338 How to read this manual .........................................................................................................1338 Coating materials list ..........................................................................................................1340 Special tools list ..............................................................................................................1344 Sketches of special tools .......................................................................................................1348 Engine and cooling system ...........................................................................................................1353 Removal and installation of supply pump assembly ................................................................................1353 Removal and installation of injector assembly ...................................................................................1360 Removal and installation of cylinder head assembly ..............................................................................1367 Removal and installation of radiator assembly ...................................................................................1375 Removal and installation of hydraulic oil cooler assembly .......................................................................1378 Removal and installation of aftercooler assembly ................................................................................1380 Removal and installation of cooling fan and fan motor assembly ..................................................................1382 Removal and installation of engine and main pump assembly .......................................................................1386 Removal and installation of engine front seal ...................................................................................1396 Removal and installation of engine rear seal ....................................................................................1400 Removal and installation of engine hood assembly ................................................................................1405 Removal and installation of KDPF assembly........................................................................................1406 Removal and installation of KCCV assembly .......................................................................................1412 Removal and installation of air cleaner assembly ................................................................................1414 Power train system ..................................................................................................................1416 Removal and installation of travel motor and final drive assembly ...............................................................1416 Disassembly and assembly of final drive .........................................................................................1417 Removal and installation of swing motor and swing machinery assembly ............................................................1425 Disassembly and assembly of swing machinery .....................................................................................1427 Removal and installation of swing circle assembly ...............................................................................1434 Undercarriage and frame .............................................................................................................1435 Separation and connection of track shoe assembly ................................................................................1435 Removal and installation of sprocket ............................................................................................1437 Removal and installation of idler and idler cushion assembly ....................................................................1438 Disassembly and assembly of idler ...............................................................................................1439 Disassembly and assembly of idler cushion .......................................................................................1442 Disassembly and assembly of track roller ........................................................................................1444 Disassembly and assembly of carrier roller ......................................................................................1445 Removal and installation of revolving frame assembly ............................................................................1447 Removal and installation of counterweight assembly ..............................................................................1449 Hydraulic system ....................................................................................................................1451 Removal and installation of center swivel joint assembly ........................................................................1451 Disassembly and assembly of center swivel joint .................................................................................1453 Removal and installation of hydraulic tank assembly .............................................................................1454 Removal and installation of main pump assembly ..................................................................................1458 Removal and installation of control valve assembly ..............................................................................1462 Disassembly and assembly of control valve .......................................................................................1466 Disassembly and assembly of work equipment PPC valve ............................................................................1471 Disassembly and assembly of travel PPC valve ....................................................................................1473 Work equipment ......................................................................................................................1475 Removal and installation of work equipment assembly .............................................................................1475 Disassembly and assembly of work equipment cylinder .............................................................................1478 Remove and install anti-drop valve assembly for boom.............................................................................1483 Remove and install anti-drop valveassembly for arm...............................................................................1485 Disassemble and assemble antidropvalve assembly..................................................................................1488 Cab and its attachments .............................................................................................................1489 Removal and installation of operator's cab assembly .............................................................................1489 Removal and installation of operator's cab glass (adhered window glass) .........................................................1494 Removal and installation of front window assembly ...............................................................................1504 Removal and installation of floor frame assembly ................................................................................1510 Removal and installation of air conditioner unit assembly .......................................................................1516 Removal and installation of operator’s seat .....................................................................................1520 Removal and installation of seat belt ...........................................................................................1522 Removal and installation of work equipment control lever assembly................................................................1523 Removal and installation of front wiper assembly ................................................................................1537 Electrical system ...................................................................................................................1544 Removal and installation of air conditioner compressor assembly .................................................................1544 Removal and installation of air conditioner condenser assembly ..................................................................1547 Removal and installation of engine controller assembly ..........................................................................1549 Removal and installation of pump controller assembly ............................................................................1551 Removal and installation of machine monitor assembly ............................................................................1554 Removal and installation of pump swash plate sensor .............................................................................1556 Removal and installation of mass air flow and temperature sensor ................................................................1557 Removal and installation of KOMTRAX terminal assembly ...........................................................................1559 60 Maintenance standard .................................................................................................................1561 Table of contents ...................................................................................................................1562 Engine and cooling system ...........................................................................................................1563 Engine mount ....................................................................................................................1563 Cooling system ..................................................................................................................1564 Cooling fan pump ................................................................................................................1565 Cooling fan motor ...............................................................................................................1567 Power train system ..................................................................................................................1568 Swing circle ....................................................................................................................1568 Swing machinery .................................................................................................................1569 Final drive .....................................................................................................................1571 Undercarriage and frame .............................................................................................................1573 Sprocket ........................................................................................................................1573 Track frame and idler cushion ...................................................................................................1575 Idler ...........................................................................................................................1576 Track roller ....................................................................................................................1578 Carrier roller ..................................................................................................................1579 Track shoe ......................................................................................................................1580 Hydraulic system ....................................................................................................................1583 Main pump .......................................................................................................................1583 Control valve ...................................................................................................................1585 Swing motor .....................................................................................................................1596 Travel motor ....................................................................................................................1598 PPC valve .......................................................................................................................1601 Solenoid valve ..................................................................................................................1608 Attachment circuit selector valve ...............................................................................................1609 Anti-drop valve for boom.........................................................................................................1610 Anti-drop valve for arm..........................................................................................................1612 Center swivel joint .............................................................................................................1614 Work equipment ......................................................................................................................1615 Work equipment ..................................................................................................................1615 Work equipment cylinder .........................................................................................................1624 80 Appendix .............................................................................................................................1627 Table of contents ...................................................................................................................1628 Air conditioner components ..........................................................................................................1629 Precautions for refrigerant .....................................................................................................1629 Air conditioner component .......................................................................................................1630 Configuration and function of refrigeration cycle ...............................................................................1633 Outline of refrigeration cycle ..................................................................................................1634 Air conditioner unit ............................................................................................................1636 Dual pressure switch ............................................................................................................1643 Air conditioner controller ......................................................................................................1644 Compressor ......................................................................................................................1645 Condenser .......................................................................................................................1646 Receiver drier ..................................................................................................................1647 Sunlight sensor .................................................................................................................1648 Outer temperature sensor (outside air temperature sensor) .......................................................................1649 Procedure for testing and troubleshooting .......................................................................................1650 Circuit diagram and arrangement of connector pins ...............................................................................1652 System diagram ..................................................................................................................1654 Input and output signals of the air conditioner controller ......................................................................1655 Parts and connectors layout .....................................................................................................1657 Layout of air conditioner related parts and connectors ..........................................................................1658 Testing air leakage (duct) ......................................................................................................1661 Testing with self-diagnosis function ............................................................................................1664 How to open the electrical system abnormality record screen in service mode of the machine monitor ..............................1665 Testing vent (mode) changeover ..................................................................................................1667 Testing FRESH/RECIRC air changeover .............................................................................................1669 Testing sunlight sensor .........................................................................................................1670 Testing (dual) pressure switch for refrigerant ..................................................................................1671 Testing relays ..................................................................................................................1673 Troubleshooting chart 1 .........................................................................................................1674 Troubleshooting chart 2 .........................................................................................................1675 Information in troubleshooting table ............................................................................................1678 Failure code list related to air conditioner ....................................................................................1679 Failure code [879AKA] A/C Inner sensor Open Circuit .............................................................................1680 Failure code [879AKB] A/C Inner sensor Short Circuit ............................................................................1681 Failure code [879BKA] A/C Outer sensor Open Circuit .............................................................................1682 Failure code [879BKB] A/C Outer sensor Short Circuit ............................................................................1684 Failure code [879CKA] Ventilating sensor Open Circuit ...........................................................................1686 Failure code [879CKB] Ventilating sensor Short Circuit ..........................................................................1687 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .....................................................................1688 Failure code [879EMC] Ventilating Damper Abnormality ............................................................................1690 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................1691 Failure code [879GKX] Refrigerant Abnormality ...................................................................................1692 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................................................1693 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................1695 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................1698 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................1700 Troubleshooting with gauge pressure .............................................................................................1702 Connection of service tool ......................................................................................................1705 Precautions for disconnecting and connecting air conditioner piping .............................................................1707 Handling of compressor oil ......................................................................................................1709 90 Diagrams and drawings ................................................................................................................1711 Table of contents ...................................................................................................................1712 Hydraulic circuit diagram ...........................................................................................................1713 Symbols in hydraulic circuit diagram ............................................................................................1713 Hydraulic circuit diagram .......................................................................................................1717 Electric circuit diagram ............................................................................................................1721 Symbols in electric circuit diagram .............................................................................................1721 Electrical circuit diagram ......................................................................................................1725 Electric circuit diagram for air conditioner unit ...............................................................................1737 INDEX....................................................................................................................................1739
DESCRIPTION:
KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05622-11 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 27/12/24
